Clamp with spring loaded bolt to repair broken exhaust manifold flange bolts

ABSTRACT

A exhaust manifold flange bolt repair system uses a spring loaded bolt to provide a quick and easy exhaust repair. The system of the present invention seals the gap in the exhaust and, when properly installed, will not come off. The repair system includes an oval clamp that can be applied to the exhaust manifold after a broken manifold bolt is removed. The oval clamp includes a female threaded portion that can be disposed over the hole of the exhaust manifold where the broken bolt was removed. A bolt can be threaded into the female threaded portion of the oval clamp, and a portion of the end of the bolt can fit into the hole in the exhaust manifold. This bolt provides a replacement manifold bolt. Springs can be disposed between a nut and the exhaust pipe flange, along the new bolt and any remaining manifold bolts.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority of U.S. provisional application No. 61/567,592, filed Dec. 6, 2011, the contents of which are herein incorporated by reference.

BACKGROUND OF THE INVENTION

The present invention relates to engine repair parts and accessories and more particularly, to an oval shaped clamp with a spring loaded bolt to repair broken exhaust manifold flange bolts.

When an exhaust flange bolt is broken, it lets exhaust fumes and noise escape from the exhaust manifold pipe. Exhaust manifold flange bolts can often break, either during use or, more frequently, when attempting an exhaust system repair. Often, when one or both exhaust manifold flange bolts break, it is difficult, if not impossible, to remove the bolt from the exhaust manifold flange. When the flange bolt is removed from the exhaust manifold flange, the female threads inside the exhaust manifold flange can become damaged, requiring additional labor of running a tap in the hole to repair the female threads.

Conventional exhaust manifold repair systems can slip off, loosen over time, or can form such a rigid connection that there is no flex so that impact to the exhaust system could result in breaks in the exhaust manifold or engine exhaust manifold.

As can be seen, there is a need for an improved system for repairing broken exhaust manifold flange bolts.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a clamp assembly comprises a female threaded end; a threaded bolt operable to thread in a first side of the female threaded end; and a loop running from one side of the female threaded end, looping about a second opposite side thereof, and attached to a second side of the female threaded end, wherein the loop forms a plane that is angled from about 3 to about 10 degrees with respect to an axis of the threaded bolt threaded into the female threaded end.

In another aspect of the present invention, a exhaust manifold flange bolt repair system comprises a clamp assembly including a female threaded end, a threaded bolt operable to thread in a first side of the female threaded end, and a loop running from one side of the female threaded end, looping about a second opposite side thereof, and attached to a second side of the female threaded end, wherein the loop forms a plane that is angled from about 3 to about 10 degrees with respect to an axis of the threaded bolt threaded into the female threaded end; a spring operable to be disposed along the axis of the threaded bolt; and a nut disposed on an end of the threaded bolt.

In a further aspect of the present invention, a method for repairing a broken exhaust manifold flange bolt comprises removing a broken flange bolt such that the broken flange bolt is in its flange bolt hole and is flush with an exhaust manifold flange; placing a clamp assembly about the flange bolt hole, wherein the clamp assembly includes a female threaded end and a loop running from one side of the female threaded end, looping about a second opposite side thereof, and attached to a second side of the female threaded end, wherein the loop forms a plane that is angled from about 3 to about 10 degrees with respect to an axis of a threaded bolt threaded into the female threaded end; tightening the threaded bolt into the female threaded end; placing an exhaust pipe flange onto the threaded bolt; placing a spring against the exhaust pipe flange; placing a nut on an end of the threaded bolt; and tightening the bolt to secure the exhaust pipe flange to the exhaust manifold flange.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exhaust manifold flange bolt repair system according to an exemplary embodiment of the present invention;

FIG. 2 is an exploded perspective view of the exhaust manifold flange bolt repair system of FIG. 1;

FIG. 3 is an exploded perspective view of a bolt system of the exhaust manifold flange bolt repair system of FIG. 1; and

FIG. 4 is a cross sectional view taken along line 4-4 of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

Broadly, an embodiment of the present invention provides an exhaust manifold flange bolt repair system that uses a spring loaded bolt to provide a quick and easy exhaust repair. The system of the present invention seals the gap in the exhaust and, when properly installed, will not come off. The repair system includes an oval clamp that can be applied to the exhaust manifold after a broken manifold bolt is removed. The oval clamp includes a female threaded portion that can be disposed over the hole of the exhaust manifold where the broken bolt was cut. A bolt can be threaded into the female threaded portion of the oval clamp, and tightened against the exhaust manifold. This bolt provides a replacement manifold bolt. Springs can be disposed between a nut and the exhaust pipe flange, along the new bolt and any remaining manifold bolts.

Referring now to FIGS. 1 through 4, an exhaust manifold 10 terminates in an exhaust manifold flange 12. The exhaust manifold flange 12 includes exhaust manifold flange bolts 14 extending from threaded holes 16 in the exhaust manifold flange 12. Typically, there are two exhaust manifold flange bolts 14, but three or even more bolts could be used. Typically, the bolts extend out the holes 16 and are secured to an exhaust pipe flange 18 of an exhaust pipe 20.

When one or more of the exhaust manifold flange bolts 14 break, the user can cut or grind the bolt down at the hole 16 so that it is generally flush with the exhaust manifold flange 12. Once this surface is prepared, the repair can continue with the use of clamp assembly 38 and replacement bolt 32.

The clamp assembly 38 can include a female threaded end 36, such as a threaded hexagonal nut, and a loop 34 attached to the female threaded end 36, forming a loop behind the female threaded end 36. The loop 34 can be an oval loop attached to opposite sides of a hexagonal nut and forming an oval loop behind the nut. The female threaded end 36 provided threads into which a replacement bolt 32 can be threaded. When the replacement bolt 32 is threaded into the female threaded end 36, the replacement bolt 32 defines an axis. The loop 34 can define a plane that is angled away from this axis from about 3 to about 10 degrees, typically about 5 degrees. This angle can be positioned towards the exhaust manifold 10 when the clamp assembly 38 is disposed on the exhaust manifold flange 12 as described below.

The clamp assembly 38 can be disposed over the exhaust manifold flange 12 where the broken bolt was cut/ground down. The angled loop 34 can be disposed pointing toward the exhaust manifold 10, as shown in FIG. 2.

The bolt 32 can be, for example, a recessed hex head (Allen-type) bolt. The bolt 32 can be threaded into the female threaded end 36 of the clamp assembly 38. The user can tighten the bolt 32 down against the hole 16 filled with the broken original flange bolt with an Allen wrench. In some embodiments, where the exhaust pipe flange 18 is welded on the exhaust pipe 20, the bolt 32 can be inserted through the exhaust pipe flange 18 before threading into the female threaded end 36 of the clamp assembly 38.

Once the bolt 32 is tightened into the female threaded end 36 of the clamp assembly 38, the bolt 32 can act as a replacement flange bolt to secure the exhaust manifold flange 12 to the exhaust pipe flange 18.

The exhaust pipe flange 18 can be placed onto the original flange bolt 14 and the replacement flange bolt 32. A washer 26 can then be disposed on the bolts 14, 32, followed by exhaust springs 30, a washer 24 and a nut 22, 28, where nut 22 is an existing flange nut and nut 28 is a replacement flange nut fitting onto the replacement bolt 32. The nuts 22, 28 can be tightened sufficiently to provide a seal between the exhaust manifold flange 12 and the exhaust pipe flange 18.

The springs 30 can provide flexibility between the exhaust pipe flange 18 and the exhaust manifold flange 12. Should the exhaust pipe 20 be struck, for example, damage to the exhaust manifold 10 can be avoided due to this flexibility in the system.

While the Figures show one of the existing flange bolts 14 being replaced by the repair system of the present invention, two (or all) of the existing flange bolts 14 can be replaced by the methods described above.

While the above description deals with repair of broken flange bolts, the clamp assembly of the present invention could be used in new, original installations as well. In this embodiment, the exhaust flange would not need to be tapped with female threads, as the clamp assembly can be secured to the flange without the use of a threaded hole. In some embodiments, the flange could be designed with a dimple recessed to receive the replacement bolt. In other embodiments, the flange could be designed with a curved wing on the end to also prevent sliding off of the clamp assembly. In any event, the clamp assembly could be used in various applications, including both exhaust repair and new exhaust assembly.

The device of the present invention could be used in other applications. For example, the clamp assembly of the present invention could be used as a custom exhaust pipe hanger, as a wire or fuel line support, as a hanger on a race car or truck, or even on buildings with metal rafters to hold up wiring. Due to the rounded edges of the oval clamp, there would be little chance that it would chaff or cut into the wire. Of course, the device, as herein described, could find use in other applications as well.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. 

What is claimed is:
 1. A clamp assembly comprising: a female threaded end; a threaded bolt operable to thread in a first side of the female threaded end; and a loop running from one side of the female threaded end, looping about a second opposite side thereof, and attached to a second side of the female threaded end, wherein the loop forms a plane that is angled from about 3 to about 10 degrees with respect to an axis of the threaded bolt threaded into the female threaded end.
 2. The clamp assembly of claim 1, wherein the female threaded end is a hexagonal nut.
 3. The clamp assembly of claim 1, further comprising a first washer and a second washer sandwiching a spring disposed along a length of the threaded bolt.
 4. An exhaust manifold flange bolt repair system comprising: a clamp assembly including a female threaded end, a threaded bolt operable to thread in a first side of the female threaded end, and a loop running from one side of the female threaded end, looping about a second opposite side thereof, and attached to a second side of the female threaded end, wherein the loop forms a plane that is angled from about 3 to about 10 degrees with respect to an axis of the threaded bolt threaded into the female threaded end; a spring operable to be disposed along the axis of the threaded bolt; and a nut disposed on an end of the threaded bolt.
 5. The exhaust manifold flange bolt repair system of claim 4, further comprising washers sandwiching the spring.
 6. The exhaust manifold flange bolt repair system of claim 5, wherein the clamp assembly is operable to secure to an exhaust manifold flange and the spring is disposed between an exhaust pipe manifold and the nut.
 7. A method for repairing a broken exhaust manifold flange bolt, comprising: removing a broken flange bolt such that the broken flange bolt is in its flange bolt hole and is flush with an exhaust manifold flange; placing a clamp assembly about the flange bolt hole, wherein the clamp assembly includes a female threaded end and a loop running from one side of the female threaded end, looping about a second opposite side thereof, and attached to a second side of the female threaded end, wherein the loop forms a plane that is angled from about 3 to about 10 degrees with respect to an axis of a threaded bolt threaded into the female threaded end; tightening the threaded bolt into the female threaded end; placing an exhaust pipe flange onto the threaded bolt; placing a spring against the exhaust pipe flange; placing a nut on an end of the threaded bolt; and tightening the bolt to secure the exhaust pipe flange to the exhaust manifold flange.
 8. The method of claim 7, further comprising disposing a first washer between the spring and the exhaust pipe flange.
 9. The method of claim 8, further comprising disposing a second washer between the spring and the nut.
 10. The method of claim 7, wherein the exhaust pipe flange is disposed on one or more existing exhaust manifold flange bolts in addition to the threaded bolt.
 11. The method of claim 7, wherein more than one broken manifold flange bolts are replaced by the clamp assembly. 